CN112578255B - Electric automobile IGBT health monitoring system based on fiber grating sensor - Google Patents
Electric automobile IGBT health monitoring system based on fiber grating sensor Download PDFInfo
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- CN112578255B CN112578255B CN202011503268.9A CN202011503268A CN112578255B CN 112578255 B CN112578255 B CN 112578255B CN 202011503268 A CN202011503268 A CN 202011503268A CN 112578255 B CN112578255 B CN 112578255B
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- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
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- G01R31/2608—Circuits therefor for testing bipolar transistors
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Abstract
The invention discloses an electric automobile IGBT health monitoring system based on a fiber grating sensor, which comprises a motor controller, an optical fiber demodulation system, a whole automobile controller, a thermal management system and an instrument, wherein the thermal management system is connected with a cooling channel of the motor controller, the motor controller comprises an IGBT power module assembly, a driving circuit module and a control circuit module, the IGBT power module assembly comprises the fiber grating sensor, six IGBT chips and six diodes, the fiber grating sensor comprises optical fibers and optical fiber joints, six fiber gratings are engraved on the optical fibers, and the six fiber gratings are respectively and correspondingly adhered to the surfaces of the six IGBT chips. According to the invention, the evaluation of the metamorphic degree of the thermal performance of the IGBT can be carried out after the IGBT power module assembly runs for a long time, and the target value of the cooling water temperature of the heat management system is matched again according to the metamorphic degree, so that a better heat dissipation environment is created for the steady-state running of the IGBT power module assembly.
Description
Technical Field
The invention belongs to the field of electric automobile safety, and particularly relates to an electric automobile IGBT health monitoring system based on a fiber grating sensor.
Background
With the continuous improvement of the performance of electric vehicles and the rapid development of automatic driving technologies, the requirements on the efficiency and reliability of electric vehicles are higher. Insulated Gate Bipolar Transistors (IGBTs) are used as core parts of electric automobile systems, and the performance and reliability of the IGBTs are very important. For the electric automobile, the uncertainty of the operation of the electric automobile is caused due to the complexity and the variability of the external environment and the operation condition, and the application environment of the IGBT is more severe. The main reason for the failure of the IGBT lies in the fast switching of large current and high voltage for a long time, and the extreme working condition can cause the working temperature of the IGBT chip to be overhigh and the temperature rise speed to be overhigh. Excessive temperatures can cause IGBT chip breakdown and the accumulated thermally induced mechanical stresses can also lead to many failures such as bond wire detachment, solder fatigue, and aluminum corrosion.
The IGBT temperature of the electric automobile is generally acquired by an NTC sensor built in an IGBT power module and then input to a motor controller for temperature monitoring and diagnosis protection. However, since the arrangement position of the NTC sensor is a certain distance away from the IGBT chip, the temperature acquired by the NTC sensor cannot reflect the real temperature rise of the IGBT chip most quickly and accurately. For example, the NTC sensor of the IGBT power module in the form of english-flying-ice is disposed at the edge of the IGBT power module, and the junction temperature change of the IGBT chip cannot be reflected in time. CN109443589A discloses an IGBT module and a temperature monitoring system of the IGBT module, which can measure the temperature of an IGBT heating element by using a fiber grating and monitor the temperature of the IGBT module in real time, but does not relate to how to monitor the IGBT health of an electric vehicle.
The IGBT power module of the electric automobile works in a severe environment with large current, high frequency and high temperature for a long time, and the thermal stress borne by the IGBT chip can cause the problems of solder fatigue, aluminum corrosion, bonding wire peeling and the like along with the lapse of time, so that the contact resistance of the bonding wire and the IGBT chip is increased probably due to the problems, the junction temperature rise of the IGBT chip finally reflected as a molting state is faster, and the junction temperature is higher at a steady-state working point; therefore, the IGBT health status of the electric vehicle needs to be monitored.
Disclosure of Invention
The invention aims to provide an electric automobile IGBT health monitoring system based on a fiber grating sensor, so as to slow down disintegration of an IGBT power module and create a better heat dissipation environment for steady-state operation of the IGBT power module.
The invention relates to an electric automobile IGBT health monitoring system based on a fiber bragg grating sensor, which comprises a motor controller, a fiber bragg grating demodulation system, a whole automobile controller, a thermal management system and an instrument, wherein the thermal management system is connected with a cooling channel of the motor controller through a water inlet pipeline and a water outlet pipeline, the motor controller comprises an IGBT power module assembly, a driving circuit module connected with the IGBT power module assembly and a control circuit module connected with the driving circuit module, the fiber bragg grating demodulation system, the control circuit module, the whole automobile controller, the thermal management system and the instrument are communicated through a CAN bus, the IGBT power module assembly comprises a fiber bragg grating sensor, six IGBT chips and six diodes, the six IGBT chips and the six diodes are welded on a circuit substrate, the six IGBT chips and the six diodes form an IGBT power module, the fiber bragg grating sensor comprises an optical fiber and an optical fiber connector connected to the end of the optical fiber, six fiber bragg gratings with different resonant wavelengths are written on the optical fiber, the six fiber bragg gratings are correspondingly adhered to the surfaces of the six IGBT chips, the optical fiber bragg grating sensor is connected with the optical fiber bragg grating demodulation system, the signal output by the fiber bragg grating sensor is collected by the fiber bragg grating sensor, the six fiber bragg grating sensor is analyzed and calculated to obtain six fiber bragg grating signals, the six IGBT temperature of the six IGBT demodulation system controls the IGBT cooling circuit to control the cooling circuit module, and the temperature of the cooling circuit is preset. The method comprises the steps that an upper deviation and a lower deviation of a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature (namely a tolerance zone of the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature) are stored in a control circuit module in advance, when the running time of an IGBT power module assembly reaches a preset time threshold, information needing to be subjected to IGBT thermal performance disintegration degree evaluation is sent to a meter for prompting, if the IGBT thermal performance disintegration degree evaluation is selected, a relation curve II between the IGBT junction temperature and the cooling water temperature in the disintegration state can be obtained, the control circuit module takes the cooling water temperature at the intersection of the relation curve II and the upper deviation of the reference curve as a matched cooling water temperature target value and sends the matched cooling water temperature target value to a whole vehicle controller, the whole vehicle controller sends the matched cooling water temperature target value to a thermal management system, and the thermal management system carries out cooling and heat dissipation on a motor controller according to the matched cooling water temperature target value.
Preferably, the control circuit module judges six IGBT junction temperature signals: if the IGBT junction temperature is too high or the IGBT junction temperature rises too fast, the information that the IGBT junction temperature is too high or the IGBT junction temperature rises too fast is sent to the vehicle control unit, and the vehicle control unit sends cooling loop maintenance information required for cooling loop faults to an instrument for prompting after receiving the information and sends a power output limiting request to the control circuit module; if the IGBT junction temperature difference is too large, sending information of the too large IGBT junction temperature difference to a vehicle control unit, sending information that the IGBT temperature difference fault needs to be maintained by an IGBT power module assembly to an instrument for prompting after the vehicle control unit receives the information, and sending a request for limiting output power to a control circuit module; after the control circuit module receives the request for limiting the output power, the drive circuit module is controlled to drive the six IGBT chips to be switched on/off in a duty ratio adjusting mode, and the limitation of the output power of the motor is achieved. By monitoring the junction temperature of the IGBT in real time, the protection strategy is implemented aiming at the conditions of over-temperature operation, over-fast temperature rise and over-large temperature difference, which is indispensable for ensuring the safe operation of the electric automobile.
Preferably, if the junction temperature of any one path of IGBT is greater than the preset highest working junction temperature of the IGBT, the control circuit module judges that the junction temperature of the IGBT is too high; if the change rate of the junction temperature of any one path of IGBT is larger than the preset change rate of the highest temperature rise of the IGBT, the control circuit module judges that the temperature rise of the junction temperature of the IGBT is too fast; and if the absolute value of the junction temperature difference of any two paths of IGBT is larger than a preset temperature difference threshold value, the control circuit module judges that the junction temperature difference of the IGBT is overlarge.
Preferably, the upper deviation and the lower deviation of a reference curve, which is stored in the control circuit module in advance and reflects the corresponding relationship between the IGBT junction temperature and the cooling water temperature, are obtained by the following method:
s1, selecting different n cooling water temperatures, communicating a cooling system of a motor rack with a cooling channel of a motor controller, and then executing S2;
s2, setting a cooling water temperature target value as a selected first cooling water temperature on the motor rack, and then executing S3;
s3, the cooling system operates according to the set cooling water temperature target value, when the cooling water temperature of the cooling system reaches the set cooling water temperature target value, the motor is controlled to stably operate at peak power, and then S4 is executed;
s4, when the junction temperature of the IGBT is kept unchanged, averaging six IGBT junction temperature signals to obtain an IGBT junction temperature average value, recording the IGBT junction temperature average value and a set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing S5;
s5, controlling the motor to stop running for a preset first time, judging whether n IGBT junction temperature average values-cooling water temperature target value data are obtained or not after the preset first time is reached, if so, executing S7, and otherwise, executing S6;
s6, setting the target value of the cooling water temperature on the motor rack as the next selected cooling water temperature, and then returning to execute the S3;
s7, fitting the n IGBT junction temperature average values-cooling water temperature target value data to obtain a fitting curve, taking the fitting curve as a relation curve I of the IGBT junction temperature and the cooling water temperature in an initial state, and then executing S8;
s8, taking a relation curve I of the IGBT junction temperature and the cooling water temperature in the initial state as a reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature, and then executing S9;
and S9, determining an upper deviation and a lower deviation of the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature.
Preferably, the specific step of evaluating the thermal performance disintegration degree of the IGBT to obtain a relation curve ii between the IGBT junction temperature and the cooling water temperature in the disintegration state includes:
p1, selecting different n cooling water temperatures, connecting a diagnostic instrument with a vehicle diagnostic interface, switching the vehicle state to a whole vehicle calibration mode through the diagnostic instrument, and then executing P2;
p2, setting the cooling water temperature target value as the selected first cooling water temperature through the diagnostic instrument, sending the set cooling water temperature target value to the heat management system by the vehicle control unit, and then executing P3;
p3, the thermal management system operates according to the set cooling water temperature target value, when the cooling water temperature in the thermal management system reaches the set cooling water temperature target value, the vehicle is enabled to run linearly at 100% of the opening degree of the accelerator pedal, and then P4 is executed;
p4, when the IGBT junction temperature is kept unchanged, averaging six IGBT junction temperature signals to obtain an IGBT junction temperature average value, recording the IGBT junction temperature average value and a set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing P5;
p5, stopping the vehicle from running for a preset first time, judging whether n IGBT junction temperature average values-cooling water temperature target value data are obtained or not after the preset first time is reached, if yes, executing P7, and otherwise, executing P6;
p6, setting the cooling water temperature target value as the next selected cooling water temperature through the diagnostic instrument, sending the set cooling water temperature target value to the heat management system by the vehicle controller, and then returning to execute P3;
and P7, fitting the n IGBT junction temperature average values-cooling water temperature target value data to obtain a fitting curve, and taking the fitting curve as a relation curve II of the IGBT junction temperature and the cooling water temperature in the molting state.
Preferably, after the matched cooling water temperature target value is sent to the vehicle controller, the control circuit module uses the obtained relation curve ii of the IGBT junction temperature and the cooling water temperature in the ecdysis state as a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature, and then determines and stores an upper deviation and a lower deviation of the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature.
Preferably, the preset time threshold is 3 years, the preset cooling water temperature target value is 60 ℃, the preset temperature difference threshold is 5 ℃, the preset maximum operating junction temperature of the IGBT is 95 ℃, the preset maximum temperature rise change rate of the IGBT is 10 ℃/ms, and the preset first time is 5 minutes.
The IGBT power module of the electric automobile works in a severe environment with large current, high frequency and high temperature for a long time, and the thermal stress borne by the IGBT chip can cause the problems of solder fatigue, aluminum corrosion, bonding wire peeling and the like along with the lapse of time, so that the contact resistance between the bonding wire and the IGBT chip is increased probably due to the problems, and finally the junction temperature of the IGBT chip in a molting state rises faster, and the junction temperature is higher at a steady-state working point. In order to slow down the disintegration of the IGBT power module, the invention starts from the aspect of actively relieving the thermal stress and takes away more heat of the IGBT chip so as to reduce the working environment temperature of the IGBT power module; therefore, the method can evaluate the metamorphic degree of the thermal performance of the IGBT after the IGBT power module assembly runs for a long time, and re-match the target value of the cooling water temperature of the thermal management system (equivalent to actively reducing the target value of the cooling water temperature) according to the metamorphic degree, so that a better heat dissipation environment is created for the steady-state running of the IGBT power module assembly, the working temperature of the IGBT power module is kept relatively stable, the service life of the IGBT power module is prolonged, and the method has great significance for improving the safety and the reliability of the electric automobile.
Drawings
Fig. 1 is a schematic structural diagram of an IGBT power module assembly according to the present invention.
FIG. 2 is a schematic block diagram of an electric vehicle IGBT health monitoring system based on a fiber grating sensor in the invention.
FIG. 3 is a flow chart of the process for controlling the circuit blocks during initial calibration according to the present invention.
Fig. 4 is a processing flow chart of the vehicle controller in the process of normally operating and monitoring the junction temperature of the IGBT in real time.
Fig. 5 is a processing flow chart of the control circuit module in the process of normally operating and monitoring the junction temperature of the IGBT in real time according to the present invention.
Fig. 6 is a processing flow chart of the vehicle control unit when the thermal performance degradation degree of the IGBT is evaluated according to the present invention.
Fig. 7 is a processing flow chart of the control circuit module when the thermal performance disintegration degree of the IGBT is evaluated according to the present invention.
FIG. 8 is a schematic diagram of matching a target value of cooling water temperature according to the present invention.
Detailed Description
The present invention will be described in detail with reference to the accompanying drawings.
The electric vehicle IGBT health monitoring system based on the fiber grating sensor shown in fig. 1 and fig. 2 includes a motor controller, an optical fiber demodulation system, a vehicle control unit 3, a thermal management system 4, and an instrument 5. The heat management system 4 is connected with a cooling channel of the motor controller through a water inlet pipeline 41 and a water outlet pipeline 42, and the heat management system 4 is provided with a temperature sensor 43 for detecting the temperature of cooling water; the motor controller comprises an IGBT power module assembly 11, a driving circuit module 12 connected with the IGBT power module assembly 11 and a control circuit module 13 connected with the driving circuit module 12; the optical fiber demodulation system comprises a broadband light source 21, an optical isolator 22, an optical circulator 23, a photoelectric converter 24 and a signal processing module 25; the signal processing module 25, the control circuit module 13, the vehicle control unit 3, the thermal management system 4, the instrument 5 communicates through a CAN bus, the IGBT power module assembly 11 includes a fiber grating sensor and six IGBT chips 112 and six diodes 113 welded on the circuit substrate, the IGBT power module is composed of the six IGBT chips 112 and the six diodes 113, the fiber grating sensor comprises an optical fiber 114 and an optical fiber connector 115 connected to the end part of the optical fiber 114, six fiber gratings 111 with different resonant wavelengths are inscribed on the optical fiber 114, and the six fiber gratings 111 correspond to each other and are adhered to the surfaces of the six IGBT chips 112 through silica gel. The optical fiber connector 115 is connected with the optical circulator 23, the optical fiber demodulation system collects signals output by the fiber bragg grating sensor and carries out analysis calculation to obtain six paths of IGBT junction temperature signals, and the working principle of the optical fiber demodulation system is as follows: the broadband light source 21 emits broadband light to enter the optical isolator 22, the optical isolator 22 limits the direction of the light, so that the light CAN be transmitted in a single direction, the broadband light enters from the port 1# of the optical circulator 23, enters the six optical fiber gratings 111 from the port 2# of the optical circulator 23 through transmission optical fibers, optical signals reflected by the six optical fiber gratings 111 enter the optical circulator 23 again through the port 2# of the optical circulator 23, the optical signals are transmitted to the photoelectric converter 24 from the port 3# of the optical circulator 23, electric signals obtained through conversion of the photoelectric converter 24 enter the signal processing module 25, the signal processing module 25 performs analysis calculation to obtain six IGBT junction temperature signals, the signal processing module 25 transmits the six IGBT junction temperature signals to the control circuit module 13 through a CAN bus, the control circuit module 13 judges the six IGBT junction temperature signals to realize real-time monitoring of the IGBT junction temperature, the thermal management system 4 cools and dissipates the motor controller according to a preset cooling target value of 60 ℃, and the purpose of taking away heat generated when the IGBT power module works is just heat failure.
The control circuit module 13 stores in advance an upper deviation and a lower deviation of a reference curve (i.e., a tolerance zone of the reference curve reflecting the corresponding relationship between the IGBT junction temperature and the cooling water temperature) reflecting the corresponding relationship between the IGBT junction temperature and the cooling water temperature, and the tolerance zone is obtained by performing initial calibration (i.e., obtained by performing IGBT thermal performance evaluation in an initial state). When the running timing time of the IGBT power module assembly 11 reaches a preset time threshold (for example, 3 years), the control circuit module 13 sends information to be subjected to IGBT thermal performance ecdysis degree evaluation to the meter 5 through the CAN bus, the meter 5 carries out IGBT thermal performance ecdysis degree evaluation prompting after receiving the information, if a user sees the prompting information, the user selects to carry out the IGBT thermal performance ecdysis degree evaluation, the vehicle is driven to a 4S shop, the vehicle state is switched to a whole vehicle calibration mode by using a diagnostic instrument, the IGBT thermal performance ecdysis degree evaluation is carried out, a relation curve ii between the IGBT junction temperature and the cooling water temperature in an ecdysis state CAN be obtained, the control circuit module 13 takes the cooling water temperature at the intersection of the upper deviation of a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature as a matched cooling water temperature target value (see point a in fig. 8, that 30 ℃ is taken as a matched cooling water temperature target value in the embodiment), and sends the cooling water temperature to the whole vehicle controller 3 through the CAN controller 3, the whole vehicle controller 3 sends the matched cooling water temperature to the CAN send the heat management system 4 through the CAN reduce the cooling water temperature of the IGBT cooling environment by more effectively (the cooling power reduction CAN be taken away by the cooling water temperature of the cooling environment with the cooling module under 30 ℃, and the stable state reduction CAN be taken away by the IGBT cooling environment.
The specific mode of real-time monitoring of the IGBT junction temperature is as follows:
the control circuit module 13 judges six IGBT junction temperature signals: if the junction temperature of any one of the IGBTs is greater than the preset highest operating junction temperature of the IGBTs (for example, 95 ℃), the control circuit module 13 determines that the junction temperature of the IGBTs is too high, if the change rate of the junction temperature of any one of the IGBTs is greater than the preset highest temperature rise change rate of the IGBTs (for example, 10 ℃/ms), the control circuit module 13 determines that the temperature rise of the junction temperature of the IGBTs is too fast, if the junction temperature of the IGBTs is too high or the temperature rise of the junction temperature of the IGBTs is too fast, the control circuit module 13 sends information that the junction temperature of the IGBTs is too high or the temperature rise of the junction temperature of the IGBTs is too fast to the vehicle controller 3 through the CAN bus, after receiving the information, the vehicle controller 3 sends cooling circuit maintenance information that the cooling circuit fault needs to the instrument 5 through the CAN bus, the instrument 5 prompts that the cooling circuit fault needs to be maintained, and simultaneously the vehicle controller 3 sends a power output limiting request to the control circuit module 13. If the absolute value of any two paths of IGBT junction temperature differences is larger than 5 ℃, the control circuit module 13 judges that the IGBT junction temperature differences are too large, if the IGBT junction temperature differences are too large, information about the too large IGBT junction temperature differences is sent to the whole vehicle controller 3 through a CAN bus, the whole vehicle controller 3 sends IGBT temperature difference faults to the instrument 5 through the CAN bus after receiving the information, the instrument 5 prompts the IGBT temperature difference faults to carry out maintenance on the IGBT power module assemblies, and meanwhile the whole vehicle controller 3 sends a power output limiting request to the control circuit module 13; after receiving the request for limiting the output power, the control circuit module 13 controls the driving circuit module 12 to drive the six IGBT chips 112 to turn on/off in a duty ratio adjusting manner, so as to limit the output power of the motor.
When the motor controller and the motor are not loaded on the vehicle, initial calibration is carried out on the motor rack, the motor controller and the motor are loaded on the motor rack, and a cooling system of the motor rack is used for replacing a thermal management system to cool and dissipate heat of the motor controller. The specific way of performing initial calibration on the motor rack to obtain the upper deviation and the lower deviation of the reference curve which is stored in the control circuit module 13 in advance and reflects the corresponding relation between the IGBT junction temperature and the cooling water temperature is as follows:
s1, selecting six different cooling water temperatures, communicating a cooling system of a motor rack with a cooling channel of a motor controller, and then executing S2;
s2, setting a target value of the cooling water temperature on the motor rack as a selected first cooling water temperature, and then executing S3;
s3, the cooling system operates according to the set cooling water temperature target value, when the cooling water temperature of the cooling system reaches the set cooling water temperature target value, the motor is controlled to stably operate at peak power, and then S4 is executed;
s4, when the IGBT junction temperature is kept unchanged, averaging the six IGBT junction temperature signals to obtain an IGBT junction temperature average value, recording (storing) the IGBT junction temperature average value and a set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing S5;
s5, controlling the motor to stop running for a preset first time (for example, 5 minutes), judging whether six IGBT junction temperature average values-cooling water temperature target value data are obtained (namely whether the six IGBT junction temperature average values-cooling water temperature target value data are stored) or not after the preset first time is reached, if so, executing S7, and otherwise, executing S6;
s6, setting the target value of the cooling water temperature on the motor rack as the next selected cooling water temperature, and then returning to execute the S3;
s7, fitting the six IGBT junction temperature average values and cooling water temperature target value data to obtain a fitting curve, taking the fitting curve as a relation curve I of the IGBT junction temperature and the cooling water temperature in an initial state, and then executing S8;
s8, taking a relation curve I of the IGBT junction temperature and the cooling water temperature in the initial state as a reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature, and then executing S9;
and S9, determining an upper deviation and a lower deviation of a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature. This determination is known in the art. The determined upper deviation and lower deviation are stored in the control circuit module 13, that is, the upper deviation and lower deviation of a reference curve which is stored in the control circuit module 13 in advance and reflects the corresponding relationship between the IGBT junction temperature and the cooling water temperature.
The specific steps of evaluating the metamorphic degree of the thermal performance of the IGBT to obtain a relation curve II of the IGBT junction temperature and the cooling water temperature in the metamorphic state comprise:
p1, selecting six different cooling water temperatures, connecting a diagnostic instrument with a vehicle diagnostic interface, switching the vehicle state to a whole vehicle calibration mode through the diagnostic instrument, and then executing P2;
p2, setting the cooling water temperature target value as the selected first cooling water temperature through the diagnostic instrument, sending the set cooling water temperature target value to the heat management system 4 by the vehicle control unit 3, and then executing P3;
p3, the thermal management system 4 operates according to the set cooling water temperature target value, when the cooling water temperature in the thermal management system 4 reaches the set cooling water temperature target value, the vehicle is enabled to run linearly at 100% of the opening degree of an accelerator pedal (corresponding to the control of the motor to stably operate at peak power), and then P4 is executed;
p4, when the IGBT junction temperature is kept unchanged (when the vehicle runs in a straight line with the opening degree of the accelerator pedal of 100 percent for about 5 to 6 seconds, the IGBT junction temperature can be stably kept unchanged), averaging the six paths of IGBT junction temperature signals to obtain an IGBT junction temperature average value, recording (storing) the IGBT junction temperature average value and a set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing P5;
p5, stopping the vehicle for 5 minutes, judging whether six IGBT junction temperature average values-cooling water temperature target value data are obtained (namely whether the six IGBT junction temperature average values-cooling water temperature target value data are stored) or not after the 5 minutes, if so, executing P7, otherwise, executing P6;
p6, setting the target value of the cooling water temperature as the next selected cooling water temperature through the diagnostic instrument, sending the set target value of the cooling water temperature to the heat management system 4 by the vehicle control unit, and then returning to execute P3;
and P7, fitting the six IGBT junction temperature average values-cooling water temperature target value data to obtain a fitting curve, and taking the fitting curve as a relation curve II of the IGBT junction temperature and the cooling water temperature in the disintegration state (the relation curve II represents the junction temperature migration condition after the IGBT power module is disintegrated).
After the matched target value of the cooling water temperature is sent to the vehicle controller 3, the control circuit module 13 uses the obtained relation curve ii of the IGBT junction temperature and the cooling water temperature in the ecdysis state as a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature (i.e., updates the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature), then determines an upper deviation and a lower deviation of the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature, and the control circuit module 13 stores the upper deviation and the lower deviation of the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature.
As shown in fig. 3 to 7, the control circuit module 13 and the vehicle controller 3 perform the following processes to realize the IGBT health monitoring of the electric vehicle.
As shown in fig. 3, the processing flow of the control circuit module 13 at the initial calibration includes:
the first step, judging whether a request for operating the motor at the peak power is received, if so, executing the second step, otherwise, ending;
secondly, controlling the motor to stably run at peak power, starting the running time timing of the IGBT power module assembly, and then executing a third step;
thirdly, when the junction temperature of the IGBT is kept unchanged, averaging six IGBT junction temperature signals to obtain an IGBT junction temperature average value, and then executing the fourth step;
fourthly, recording (storing) the IGBT junction temperature average value and the set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing the fifth step;
step five, judging whether a motor operation stopping request is received, if so, executing the step six, otherwise, continuously executing the step five;
sixthly, controlling the motor to stop running for 5 minutes, and then executing the seventh step;
seventhly, judging whether six IGBT junction temperature average values-cooling water temperature target value data are obtained or not, if so, executing the eighth step, and otherwise, executing the eleventh step;
eighthly, fitting the six IGBT junction temperature average values and the cooling water temperature target value data to obtain a fitting curve, taking the fitting curve as a relation curve I of the IGBT junction temperature and the cooling water temperature in the initial state, and then executing the ninth step;
ninth, taking a relation curve I of the IGBT junction temperature and the cooling water temperature in the initial state as a reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature, and then executing the tenth step;
tenth, determining and storing an upper deviation and a lower deviation of a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature, and then ending;
step eleven, judging whether a request for operating the motor at peak power is received, if so, executing the step twelfth, otherwise, ending;
and step ten, controlling the motor to stably run at peak power, and then returning to execute the step three.
As shown in fig. 4, the processing flow of the vehicle controller 3 in the normal operation process of monitoring the IGBT junction temperature in real time includes:
the first step, judging whether information that the IGBT junction temperature is too high or the IGBT junction temperature rises too fast is received, if so, executing the second step, otherwise, executing the third step;
secondly, sending cooling loop maintenance information required for cooling loop faults to the instrument 5, and then executing a fifth step;
step three, judging whether information of overlarge temperature difference of the IGBT junction temperature is received or not, if so, executing the step four, and if not, finishing;
fourthly, sending the information that the IGBT temperature difference fault needs to be maintained to the instrument 5, and then executing the fifth step;
and fifthly, sending a request for limiting the output power to the control circuit module, and then ending.
As shown in fig. 5, the processing flow of the control circuit module 13 in the process of monitoring the IGBT junction temperature in real time in normal operation includes:
the first step, judging whether the junction temperature of any path of IGBT is larger than 95 ℃, if so, executing the second step, otherwise, executing the third step;
secondly, judging whether the junction temperature of the IGBT is too high, sending the information of the too high junction temperature of the IGBT to a vehicle controller, and then executing a seventh step;
step three, judging whether the change rate of any one path of IGBT junction temperature is more than 10 ℃/ms, if so, executing the step four, otherwise, executing the step five;
fourthly, judging that the temperature rise of the IGBT junction temperature is too fast, sending information of the too fast temperature rise of the IGBT junction temperature to the whole vehicle controller, and then executing the seventh step;
fifthly, judging whether the absolute value of the junction temperature difference of any two paths of IGBT is larger than 5 ℃, if so, executing the sixth step, otherwise, ending;
sixthly, judging that the temperature difference of the junction temperature of the IGBT is too large, sending the information of the too large temperature difference of the junction temperature of the IGBT to the vehicle controller, and then executing the seventh step;
step seven, judging whether a request for limiting output power is received, if so, executing the step eight, otherwise, ending;
and eighthly, limiting the output power of the motor (controlling the drive circuit module 12 to drive the six IGBT chips 112 to be switched on/off in a duty ratio adjusting mode to limit the output power of the motor), and ending.
As shown in fig. 6, when the thermal ecdysis degree of the IGBT is evaluated (corresponding to the vehicle calibration mode), the processing flow of the vehicle controller 3 includes:
the first step, judging whether a set cooling water temperature target value is received, if so, executing the second step, otherwise, ending;
secondly, sending the set target value of the cooling water temperature to a heat management system 4, and then executing a third step;
step three, judging whether a 100% accelerator pedal opening signal is received, if so, executing the step four, otherwise, returning to execute the step one;
step four, sending a motor operation request with peak power to the control circuit module, and then executing the step five;
step five, judging whether a signal that the opening degree of an accelerator pedal is 0 is received, if so, executing the step six, otherwise, continuously executing the step five;
sixthly, sending a motor operation stopping request to the control circuit module, and then executing seven steps;
step seven, judging whether the matched cooling water temperature target value is received or not, if so, executing the step eight, otherwise, returning to execute the step one;
and step eight, sending the matched cooling water temperature target value to the thermal management system, and then finishing.
As shown in fig. 7, the processing flow of the control circuit module 13 in the IGBT thermal performance disintegration degree evaluation includes:
the method comprises the steps that firstly, whether the running timing time of the IGBT power module assembly reaches 3 years or not is judged, if yes, the second step is executed, and if not, the operation is finished;
secondly, sending information for evaluating the thermal performance disintegration degree of the IGBT to an instrument 5, and then executing a third step;
step three, judging whether a request for operating the motor at the peak power is received, if so, executing the step four, otherwise, ending;
step four, controlling the motor to stably run at peak power, and then executing step five;
fifthly, when the IGBT junction temperature is kept unchanged, averaging the six IGBT junction temperature signals to obtain an IGBT junction temperature average value, and then executing the sixth step;
sixthly, recording (storing) the IGBT junction temperature average value and the set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing the seventh step;
step seven, judging whether a motor operation stopping request is received, if so, executing the step eight, otherwise, continuously executing the step seven;
step eight, controlling the motor to stop running for 5 minutes, and then executing the step nine;
ninthly, judging whether six IGBT junction temperature average values-cooling water temperature target value data are obtained (stored), if so, executing the tenth step, otherwise, returning to execute the third step;
tenth step, fitting the six IGBT junction temperature average values-cooling water temperature target value data to obtain a fitting curve, taking the fitted curve as a relation curve II of IGBT junction temperature and cooling water temperature in an ecdysis state, and then executing the eleventh step;
step ten, taking the cooling water temperature at the intersection of the upper deviation of a relation curve II of the IGBT junction temperature and the cooling water temperature in the molting state and a reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature as a matched cooling water temperature target value, sending the cooling water temperature to the whole vehicle controller 3, and then executing the step twelfth;
the twelfth step, resetting the running timing time of the IGBT power module assembly, and then executing the thirteenth step;
step thirteen, taking a relation curve II of the IGBT junction temperature and the cooling water temperature in the deciduate state as a reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature, and then executing the step fourteenth;
and fourteenth, determining and storing the upper deviation and the lower deviation of a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature, and then ending.
Claims (7)
1. An electric automobile IGBT health monitoring system based on a fiber bragg grating sensor comprises a motor controller, a fiber demodulation system, a whole automobile controller (3), a thermal management system (4) and an instrument (5), wherein the thermal management system (4) is connected with a cooling channel of the motor controller through a water inlet pipeline (41) and a water outlet pipeline (42), the motor controller comprises an IGBT power module assembly (11), a driving circuit module (12) connected with the IGBT power module assembly (11) and a control circuit module (13) connected with the driving circuit module (12), the fiber demodulation system, the control circuit module (13), the whole automobile controller (3), the thermal management system (4) and the instrument (5) are communicated through a CAN bus, the IGBT power module assembly (11) comprises a fiber bragg grating sensor and six IGBT chips (112) and six diodes (113) welded on a circuit substrate, the fiber bragg grating sensor comprises an optical fiber (114) and an optical fiber connector (115) connected to the end of the optical fiber bragg grating sensor (114), six fiber bragg gratings (111) with different resonant wavelengths are engraved on the optical fiber (114), the fiber bragg grating sensor is respectively adhered to the surface of the six IGBT chips (112) and connected with the thermal management system, the fiber bragg grating sensor is used for acquiring six fiber bragg grating signals, the IGBT signal demodulation signal of the IGBT power module (111) and calculating the six fiber bragg grating signal of the IGBT system, the IGBT demodulation system is used for calculating the IGBT demodulation system, and calculating junction temperature of the IGBT system, and calculating the IGBT system is obtained by the IGBT power, the optical fiber demodulation system sends six IGBT junction temperature signals to the control circuit module (13), and the heat management system (4) cools and dissipates the heat of the motor controller according to a preset cooling water temperature target value; the method is characterized in that: the upper deviation and the lower deviation of a reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature are stored in the control circuit module (13) in advance, when the running timing time of the IGBT power module assembly (11) reaches a preset time threshold, information needing to be subjected to IGBT thermal performance disintegration degree evaluation is sent to the instrument (5) for prompting, if the IGBT thermal performance disintegration degree evaluation is selected, a relation curve II between the IGBT junction temperature and the cooling water temperature in the disintegration state can be obtained, the control circuit module (13) takes the cooling water temperature at the intersection of the relation curve II and the upper deviation of the reference curve as a matched cooling water temperature target value and sends the matched cooling water temperature target value to the whole vehicle controller (3), the whole vehicle controller (3) sends the matched cooling water temperature target value to the thermal management system (4), and the thermal management system (4) carries out cooling and heat dissipation on the motor controller according to the matched cooling water temperature target value.
2. The fiber grating sensor-based IGBT health monitoring system for the electric vehicle according to claim 1, characterized in that: the control circuit module (13) judges six IGBT junction temperature signals:
if the IGBT junction temperature is too high or the IGBT junction temperature rises too fast, the information that the IGBT junction temperature is too high or the IGBT junction temperature rises too fast is sent to the whole vehicle controller (3), the whole vehicle controller (3) sends cooling loop maintenance information required for cooling loop faults to the instrument (5) for prompting after receiving the information, and sends a request for limiting output power to the control circuit module (13); if the temperature difference of the IGBT junction temperature is overlarge, sending information that the temperature difference of the IGBT junction temperature is overlarge to a vehicle control unit (3), sending information that the IGBT temperature difference fault needs to be maintained by an IGBT power module assembly to an instrument (5) for prompting after the vehicle control unit (3) receives the information, and sending a request for limiting output power to a control circuit module (13); after the control circuit module (13) receives the request for limiting the output power, the drive circuit module (12) is controlled to drive the six IGBT chips (112) to be switched on/off in a duty ratio adjusting mode, and the limitation of the output power of the motor is achieved.
3. The fiber grating sensor-based IGBT health monitoring system for the electric vehicle according to claim 2, characterized in that: if the junction temperature of any one path of IGBT is larger than the preset highest working junction temperature of the IGBT, the control circuit module (13) judges that the junction temperature of the IGBT is too high; if the change rate of the junction temperature of any one path of IGBT is larger than the preset change rate of the highest temperature rise of the IGBT, the control circuit module (13) judges that the temperature rise of the junction temperature of the IGBT is too fast; and if the absolute value of the temperature difference of the junction temperatures of any two paths of IGBTs is larger than a preset temperature difference threshold value, the control circuit module (13) judges that the temperature difference of the junction temperatures of the IGBTs is overlarge.
4. The fiber grating sensor-based IGBT health monitoring system for the electric vehicle according to claim 3, characterized in that: the upper deviation and the lower deviation of the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature are obtained in the following mode:
s1, selecting n different cooling water temperatures, communicating a cooling system of a motor rack with a cooling channel of a motor controller, and then executing S2;
s2, setting a cooling water temperature target value as a selected first cooling water temperature on the motor rack, and then executing S3;
s3, the cooling system operates according to the set cooling water temperature target value, when the cooling water temperature of the cooling system reaches the set cooling water temperature target value, the motor is controlled to stably operate at peak power, and then S4 is executed;
s4, when the junction temperature of the IGBT is kept unchanged, averaging six IGBT junction temperature signals to obtain an IGBT junction temperature average value, recording the IGBT junction temperature average value and a set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing S5;
s5, controlling the motor to stop running for a preset first time, judging whether n IGBT junction temperature average values-cooling water temperature target value data are obtained or not after the preset first time is reached, if yes, executing S7, and if not, executing S6;
s6, setting the target value of the cooling water temperature on the motor rack as the next selected cooling water temperature, and then returning to execute the S3;
s7, fitting n IGBT junction temperature average values-cooling water temperature target value data to obtain a fitting curve, taking the fitting curve as a relation curve I of the IGBT junction temperature and the cooling water temperature in an initial state, and then executing S8;
s8, taking a relation curve I of the IGBT junction temperature and the cooling water temperature in the initial state as a reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature, and then executing S9;
and S9, determining an upper deviation and a lower deviation of the reference curve reflecting the corresponding relation between the IGBT junction temperature and the cooling water temperature.
5. The fiber grating sensor-based IGBT health monitoring system for the electric vehicle according to claim 4, characterized in that: the specific steps of evaluating the thermal performance disintegration degree of the IGBT to obtain a relation curve II of IGBT junction temperature and cooling water temperature in the disintegration state comprise:
p1, selecting different n cooling water temperatures, connecting a diagnostic instrument with a vehicle diagnostic interface, switching the vehicle state to a whole vehicle calibration mode through the diagnostic instrument, and then executing P2;
p2, setting the cooling water temperature target value as the selected first cooling water temperature through the diagnostic instrument, sending the set cooling water temperature target value to a heat management system (4) by the vehicle control unit, and then executing P3;
p3, the thermal management system (4) operates according to the set cooling water temperature target value, when the cooling water temperature in the thermal management system (4) reaches the set cooling water temperature target value, the vehicle is enabled to run in a straight line at 100% of the opening degree of the accelerator pedal, and then P4 is executed;
p4, when the IGBT junction temperature is kept unchanged, averaging six IGBT junction temperature signals to obtain an IGBT junction temperature average value, recording the IGBT junction temperature average value and a set cooling water temperature target value to obtain IGBT junction temperature average value-cooling water temperature target value data, and then executing P5;
p5, stopping the vehicle from running for a preset first time, judging whether n IGBT junction temperature average values-cooling water temperature target value data are obtained or not after the preset first time is reached, if so, executing P7, otherwise, executing P6;
p6, setting the cooling water temperature target value as the next selected cooling water temperature through the diagnostic instrument, sending the set cooling water temperature target value to the heat management system (4) by the vehicle control unit, and then returning to execute P3;
and P7, fitting the n IGBT junction temperature average values-cooling water temperature target value data to obtain a fitting curve, and taking the fitting curve as a relation curve II of the IGBT junction temperature and the cooling water temperature in the molting state.
6. The fiber grating sensor-based IGBT health monitoring system for the electric vehicle according to claim 5, characterized in that: after the control circuit module (13) sends the matched cooling water temperature target value to the vehicle control unit (3), the obtained relation curve II of the IGBT junction temperature and the cooling water temperature in the disintegration state is used as a reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature, and then the upper deviation and the lower deviation of the reference curve reflecting the corresponding relation of the IGBT junction temperature and the cooling water temperature are determined and stored.
7. The fiber grating sensor-based IGBT health monitoring system for the electric vehicle as claimed in any one of claims 3 to 6, wherein: the preset time threshold is 3 years, the preset cooling water temperature target value is 60 ℃, the preset temperature difference threshold is 5 ℃, the preset maximum IGBT operating junction temperature is 95 ℃, the preset maximum IGBT temperature rise change rate is 10 ℃/ms, and the preset first time is 5 minutes.
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